Packaging and de-packaging methods using shape memory polymers

ABSTRACT

Packaging and de-packaging methods using shape memory polymers are disclosed herein. An embodiment of the packaging method involves placing a part adjacent to shape memory polymer in its permanent shape, heating the shape memory polymer to a temperature above its switching temperature, and applying a force to the heated shape memory polymer such that the polymer switches from its permanent shape into a temporary shape. The temporary shape of the shape memory polymer conforms to at least one of i) a shape of the part, or ii) a desired shape for packaging the part. The method further includes cooling the shape memory polymer to a temperature below its switching temperature to set the temporary shape.

TECHNICAL FIELD

The present disclosure relates generally to packaging and de-packagingmethods using shape memory polymers.

BACKGROUND

Current packaging techniques typically involve wrapping a part with asuitable primary packaging material. For example, a typical packagingtechnique is the thermoforming of a packaging polymer (e.g.,polyethylene) into a shape closely matching that of the part to bepackaged. Removal of the part from such packaging is often accomplishedby tearing off or cutting the packaging material, which may be difficultor require sharp removal tools.

SUMMARY

A packaging method is disclosed herein. The packaging method includesplacing a part adjacent to a shape memory polymer in its permanentshape; heating the shape memory polymer in the permanent shape to atemperature above its switching temperature; applying a force to theheated shape memory polymer such that it conforms to at least one of i)a shape of the part, or ii) a desired shape for packaging the part,thereby changing the shape memory polymer from the permanent shape tothe temporary shape; and cooling the shape memory polymer to atemperature below the switching temperature to set the shape memorypolymer into the temporary shape.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of the present disclosure will become apparentby reference to the following detailed description and drawings, inwhich like reference numerals correspond to similar, though perhaps notidentical, components. For the sake of brevity, reference numerals orfeatures having a previously described function may or may not bedescribed in connection with other drawings in which they appear.

FIGS. 1A through 1C together schematically depict an example of apackaging and de-packaging method;

FIGS. 2A through 2C together schematically depict another example of apackaging and de-packaging method;

FIGS. 3A through 3C together schematically depict yet another example ofa packaging and de-packaging method;

FIGS. 4A through 4C together schematically depict yet another example ofa packaging and de-packaging method;

FIGS. 5A through 5C together schematically depict yet another example ofa packaging and de-packaging method; and

FIGS. 6A through 6D together schematically depict an example of stillanother packaging and de-packaging method.

DETAILED DESCRIPTION

Embodiment(s) of the method, as disclosed herein, may be used tosuitably package a part, where such packaging advantageously protectsthe part from various environmental effects including, e.g., vibration,temperature, humidity, moisture, corrosive materials and/or chemicals,and/or the like. In some instances, the packaging also protects the partfrom theft or other similar undesirable (and potentially unlawful)occurrences. The methods disclosed herein may also advantageously enablede-packaging of the part, whereby upon removal of the part from thepackaging material, the packaging material may be reused for the samepart (such as, e.g., if the part requires re-packaging to return thepart to the vendor, the manufacturer, or after appropriate recycling bythe consumer or manufacturer for packaging of similar sized (e.g., whenthe temporary shape takes on the part shape) or identical (e.g., whenthe permanent shape is the part shape) future manufactured parts, or thelike). The de-packaging of the part may also be accomplished relativelyquickly in a relatively easy manner as such methods generally do notrequire the use of additional tools (e.g., box cutter, scissors, etc.).As such, the de-packaging methods disclosed herein are generally easier,and in some instances may involve less risk of damage to both theconsumer and to the part, than conventional de-packaging methods.

The term “part” as used herein refers to any type of good for whichpackaging is desired and/or necessary. The part may include food orpharmaceutical items, manufactured items (e.g., automobile parts,clothing, toys, household items, cosmetics, medical equipment,electronics etc.), boxes and or other materials for shipping such items,or the like.

Various examples of the packaging and de-packaging method utilizing ashape memory polymer with the packaged part shape as the temporary shapeare disclosed herein in conjunction with the FIGS. 1, 2, 3, 4 and 5series. Each of these examples uses a shape memory polymer (alone or inconjunction with another non-shape memory material (e.g., a conventionalpolymer, paper, fabric, metal, etc.)) as a packaging material. As usedherein, the term “packaging material” refers to a shape memory material(used alone or in conjunction with another non-shape memory material)that may be used to enclose or protect the part during distribution,storage, sale, shipment, and/or the like. As previously mentioned, insome examples, such as shown in the FIG. 1 series, the packagingmaterial is formed completely from the shape memory polymer. Also aspreviously mentioned, in other examples, such as shown in the FIG. 2through 5 series, the packaging material is formed from a combination ofthe shape memory polymer and the non-shape memory material. In theseexamples, the packaging material is a composite polymer in whichportions are made up of the shape memory polymer and other portions aremade up of the non-shape memory polymer.

Another example of the packaging and de-packaging method utilizing ashape memory polymer with the packaged part shape as the permanent shapeis disclosed herein in conjunction with the FIG. 6 series.

The shape memory polymer for use as the packaging material will beidentified herein in conjunction with the figures by reference numeral10. The shape memory polymer 10 is generally deformable from a permanentshape (identified by reference numeral 10′) to a temporary shape(identified by reference numeral 10″), and vice versa. The permanentshape 10′ of the shape memory polymer 10 refers to a memorized shape ofthe polymer 10. The temporary shape 10″ of the shape memory polymer 10refers to a deformed, non-memorized shape of the polymer 10. In someinstances, the temporary shape 10″ conforms to the shape of the part(designated reference numeral 12 in the figures) to be packaged. Inthese instances, the permanent shape 10′ of the shape memory polymer 10is also generally more open than the temporary shape 10″, especially ininstances in which the entire packaging material consists of the shapememory polymer 10. In other instances, the permanent shape 10′ conformsto the shape of the part 12 to be packaged. In these instances, thetemporary shape 10″ of the shape memory polymer 10 is also generallymore open than the permanent shape 10′, especially in instances in whichthe entire packaging material consists of the shape memory polymer 10.As used herein, the phrase “more open” refers to an expanded version ofthe shape memory polymer 10 when compared to the temporary shape 10″. Asone example, if the permanent shape 10′ is a circular shape having apredetermined diameter, it is “more open” than the temporary shape 10″when the temporary shape 10″ has a similar circular shape with a smallerdiameter than the predetermined diameter for the permanent shape 10′.The deforming of the shape memory polymer 10 will be described infurther detail below.

Prior to actually packaging a part 12, the shape memory polymer 10 isoriginally formed into a shape sufficient for packaging the part 12,where such shape is memorized by the shape memory polymer 10. Toreiterate from above, the memorized shape is referred to herein as thepermanent shape 10′ of the shape memory polymer 10. The permanent shape10′ of the shape memory polymer 10 may be any shape that is more openthan a shape of the part 12. A non-limiting example of such a permanentshape 10′ is a flat shape, as shown in FIGS. 1A, 2A, 3A, 4A and 5A. Itis to be understood, however, that other shapes may also be used for thepermanent shape 10′, such as, e.g., a curved shape (convex or concave),a parallelepiped shape, and/or the like. These other shapes, if used asthe permanent shape 10′, generally include an opened portion so that thepart 12 may be placed inside prior to packaging and may be removed uponde-packaging.

Forming the shape memory polymer 10 into its permanent shape 10′ may beaccomplished following traditional techniques, such as polymer casting,extrusion, injection molding, etc. Thermoplastic-based shape memorypolymers are formed (and shaped) above their highest meltingtemperature, and are subsequently cooled for use. Thermoset-based shapememory polymers require that the reactants be mixed and shapedconcurrently with being heated to a predetermined curing temperature toallow for setting of the permanent shape 10′ of the shape memory polymer10 and for creation of covalent bonds. If it is desired,thermoplastic-based shape memory polymers (such as polyolefin-basedpolymers) could also be made as thermoset-based shape memory polymerswith covalent crosslinking by exposing the polymer to e-beam irradiationfollowing the initial heating/shaping/cooling stage or by addingadequate crosslinkable functionalities to the initial reactant mixture.

The shape memory polymer 10 may be a thermoplastic polymer or athermoset polymer. If the shape memory polymer 10 is a thermoplasticpolymer, the recovery of the permanent shape 10′ is enabled by physicalcross-links present in the polymeric structure. If the shape memorypolymer 10 is a thermoset polymer, the recovery of the permanent shape10′ is enabled by the covalent cross-links. In either case, the presenceof physical or covalent cross-links provides the elastic energynecessary for the reversion of the shape memory polymer 10 from anothershape (e.g., a temporary shape 10″ as described in further detail below)to its permanent shape 10′ by releasing the stored energy imparted tothe system during the deformation at a suitable temperature andsubsequent cooling to set a temporary shape 10″.

Referring now to the example of the packaging method depicted in theFIG. 1 series, the method includes placing the part 12 adjacent to theshape memory polymer 10 in its permanent shape 10′. As shown in FIG. 1A,the part 12 is placed against the shape memory polymer 10, 10′. Inanother example, the shape memory polymer 10, 10′ may be placed over thepart 12. In any event, the placement of the part 12 may be made in/onany desirable location of the shape memory polymer 10, 10′. As shown inFIG. 1A, the part 12 is placed toward the middle of the flat-shapedshape memory polymer 10, 10′. In another example, the part 12 may beplaced closer to one of the ends of the shape memory polymer 10, 10′.

Depending on the placement of the part 12, at least one portion of theshape memory polymer 10, 10′ is moved during the packaging process inorder to drape the polymer 10, 10′ over the entire periphery of the part12, thereby surrounding the part 12 and/or conforming to the part 12shape. If, for example, the part 12 is placed in the middle of the shapememory polymer 10, 10′ (as shown in FIG. 1A), then the portion of thepolymer 10, 10′ located at each opposed end thereof is moved duringpackaging such that it conforms to the part 12 shape. If, on the otherhand, the part 12 is placed on the shape memory polymer 10, 10′ at oneend thereof, then the portion of the polymer 10, 10′ at the opposed endfrom where the part 12 is placed is moved during packaging such that itconforms to the part 12 shape.

In instances where the permanent shape 10′ of the shape memory polymer10 is curved, parallelepipedic, or some other similar, enclosed shape,the shape memory polymer 10, 10′ may include an opened portionconfigured to receive the part 12 (not shown in the figures). Once thepart 12 is placed inside the polymer 10, 10′, the polymer 10, 10′substantially surrounds the part 12, and thus the part 12 is adjacent tothe shape memory polymer 10, 10′.

It is to be understood that, for any of the examples described above,although the shape memory polymer 10, 10′ is adjacent to and in someinstances substantially surrounds the part 12, the shape memory polymer10 in its permanent shape 10′ generally does not actually contact allsurfaces of the part 12 (or does not effectively enclose/package thepart 12). Such contact (or such effective enclosure, packaging, and/orprotection which may not require actual contact) is accomplished whenthe shape memory polymer 10 is deformed into its temporary shape 10″,which will now be described in detail in conjunction with FIG. 1B.

Referring to FIG. 1B, the shape memory polymer 10 is deformed from itspermanent shape 10′ into its temporary shape 10″. In an example, thedeforming is accomplished by heating the shape memory polymer 10 in itspermanent shape 10′ to a temperature above its switching temperature. Asused herein, the “switching temperature” of the shape memory polymer 10refers to the temperature at which the shape memory polymer 10 becomessubstantially easily deformable and, in combination with a force (aswill be described in further detail below), may be switched from itspermanent shape 10′ into its temporary shape 10″. The switchingtemperature also refers to the temperature at which the shape memorypolymer reaches its low modulus state and may spontaneously revert fromits temporary shape 10″ back into its permanent shape 10′ (which willalso be described in further detail hereinbelow).

It is to be understood that the switching temperature varies dependingon the chemistry of the shape memory polymer 10 selected. It is to befurther understood that the switching temperature will also depend, atleast in part, on the storage temperature requirements for the packagedgoods (e.g., part 12). Additionally, because the reversion of the shapememory polymer 10 to the more open shape will occur relatively quickly(within seconds) upon heating, the undesirable effect of local heatingon the good may not deleteriously affect the product function orviability. As such, the selection of the polymer 10 (and thus theswitching temperature) will depend upon each particular product to bepackaged. For example, for electronics, typical storage temperaturerequirements are <50° C., and thus a switching temperature of that orderwould require actual heating to about 60° C. or 70° C. for a timeranging from a few tens of seconds to a few minutes. As another example,food products may or may not require refrigeration, and thus theswitching temperatures may range from 40° C. to 50° C., or from belowfreezing temperature (e.g., −30° C.) up to room temperature (e.g., about30° C.) for frozen or refrigerated products. Similarly, some medicalequipment requires storage at about or close to room temperature, andthus suitable switching temperatures for the shape memory polymer 10packaging may range from 40° C. to 50° C. (requiring heating from 50° C.to 60° C. or even up to 70° C.). Since some materials may not be viableif heated for a few seconds, and others may be viable with such heating,one will (and in some instances must) select the polymer 10 based uponthe product to be packaged, and the properties of the polymer 10. In anon-limiting example, the switching temperature of the shape memorypolymer 10 ranges from about room temperature (e.g., about 30° C.), orbelow if required, to about 160° C. for acrylate or polyolefin basedshape memory polymers 10. In non-limiting examples, polyethylene andpolypropylene-based shape memory polymers 10 would preferentially allowfor switching temperatures ranging from about 120° C. to about 160° C.,whereas the switching temperature for ethylene propylene-diene(EPDM)-based or acrylate-based shape memory polymers could respectivelyspan over a temperature range from 40° C. to about 70° C. or from belowroom temperature to about 115° C.

Non-limiting examples of suitable shape memory polymers 10 for thepackaging material include olefin-based systems, acrylate-based systems,styrene-based systems, polyester-based systems,acrylonitrile-butadiene-styrene-based blends, or epoxy-based systems.Such materials may also include fillers (e.g., inorganic fillers) orother active materials (such as, e.g., shape memory alloy wires,magneto-responsive fillers, electroactive fillers, photo-responsiveorganic dyes, and/or the like). It is to be understood that fillers maybe reinforcing fillers (which improve the mechanical properties of theshape memory polymer 10), active fillers such as, e.g., magnetic orelectrically conductive particles (which may contribute to thetriggering mechanism for the shape memory effect), or active fillersthat may contribute to improvement of other physical properties of theshape memory polymer such as, e.g., its thermal conductivity. Also, theshape memory polymers 10 may include other additives, such as UVblockers, plasticizers, colorant dyes, or other additives suitable for aparticular application.

It is to be understood that when the shape memory polymer 10 is heatedto deform the polymer 10 from the permanent shape 10′ to the temporaryshape 10″, such heating should not melt or degrade the shape memorypolymer 10, or otherwise deteriorate the operability and/orfunctionality of the part 12. Accordingly, the heating of the shapememory polymer 10 may be accomplished at a temperature above theswitching temperature of the polymer 10, but below at least a melting ordegradation temperature of the part 12 or a component of the part 12having the lowest melting or degradation temperature of all the partcomponents. In instances where the part 12 is sensitive to temperature,the selection of the shape memory polymer 10 will be such that thetemperature at which the shape memory polymer 10 is heated to switch itto/from its permanent shape to its temporary shape does notdeleteriously affect and thus accommodates such temperature sensitivity.

In addition to heating the shape memory polymer 10 to change it from itspermanent shape 10′ to its temporary shape 10″, a force is applied tothe polymer 10 to conform the shape memory polymer 10 to the part 12shape. In some instances, the heat and the force is appliedsequentially, and in other instances, the heat and the force is appliedsubstantially simultaneously.

In an example, the shape memory polymer 10 may be heated and thereafterpressurized (in a manner similar to a blister line) in order to conformthe polymer 10 to the part 12 shape. For instance, the shape memorypolymer 10 may be heated to a temperature above its switchingtemperature and then be introduced into a forming station. In theforming station, the shape memory polymer 10 is placed on the part 12and a pressure differential is applied across the shape memory polymerplane such that it conforms against the exterior of the part 12. Thepressure differential may be accomplished by applying pressure on oneside of the shape memory polymer 10, or by applying pressure to a sideof the shape memory polymer 10 furthest from the part 12 and pulling avacuum from the side of the shape memory polymer 10 facing the part 12,or by alone pulling a vacuum from the side of the shape memory polymer10 facing the part 12. In a non-limiting example, the amount of pressureapplied to the shape memory polymer 10 ranges from about 4 bars to about8 bars. It is to be understood that the shape memory polymer 10 iseffectively stretched onto the part 12 via the force from the pressureand/or vacuum which is sufficient to deform the heated shape memorypolymer 10 into its temporary shape 10″.

Once the shape memory polymer 10 has been changed from its permanentshape 10′ into its temporary shape 10″, the temporary shape 10″ of theshape memory polymer 10 may be fixed or set by cooling the shape memorypolymer 10, 10″ to a temperature below its switching temperature. Insome instances, cooling may be accomplished by removing the heat andallowing the shape memory polymer 10 to reach room temperature. In otherinstances, the shape memory polymer 10 may be cooled more rapidly by aircooling, liquid nitrogen cooling, or other suitable means. It is to beunderstood that any temperature below the switching temperature willsuffice to set the shape memory polymer 10 into the temporary shape 10″,including temperatures above or below room temperature. In anon-limiting example, the shape memory polymer 10, 10″ is desirablycooled to a temperature ranging from about at least 10° C. to about 20°C. below its switching temperature.

Referring now to FIG. 1C, the method may further include de-packagingthe part 12 after the part 12 has been packaged. In an example,de-packaging may be accomplished by heating the shape memory polymer 10in its temporary shape 10″ to a temperature above its switchingtemperature. When the shape memory polymer 10, 10″ is heated to thistemperature, the polymer 10, 10″ reaches its low modulus and deformablestate and reverts back to its permanent shape 10′. It is to beunderstood that because the reversion of the shape memory polymer 10from its temporary shape 10″ back into its permanent shape 10′ is due,at least in part, to stored energy within the polymer network, a forceis generally not required to complete the reversion.

The reverting of the shape memory polymer 10 from its temporary shape10″ back into its permanent shape 10′ opens up the shape memory polymer10 thereby releasing the part 12. Such releasing of the part 12generally enables quick and relatively safe removal of the part 12 fromthe shape memory polymer 10 packaging. The part 12 is thereafter removedfrom the packaging.

Other examples of the packaging method are schematically depicted in theFIGS. 2, 3, 4, and 5 series. In these examples, the packaging materialis a composite of a shape memory polymer 10 and a non-shape memorymaterial (identified by reference numeral 16). The non-shape memorymaterial 16 (as denoted by its name) is a material not having shapememory characteristics. Non-limiting examples of suitable non-shapememory materials include metals, paper, cardboard, non-shape memorypolymers (e.g., polyolefins, such as polyethylene terephthalate (PET),polyethylene terephthalate ethylene (PETE), polypropylene (PP), etc.), aceramic, a glass, or combinations thereof. Depending upon the purposefor the packaging and the part 12 to be packaged, non-shape memorypolymers may be the most desirable material for the non-shape memorymaterial 16.

In the example shown in the FIG. 2 series, the part 12 is placed on thepackaging material including the shape memory polymer 10 in itspermanent shape 10′ integrated with the non-shape memory material 16. Asshown in FIG. 2A, the shape memory polymer 10, 10′ is located betweentwo portions of the non-shape memory material 16. In the example shownin the FIG. 3 series, on the other hand, the shape memory polymer 10,10′ is located at an end 18 of the non-shape memory material 16. Ineither example, the shape memory polymer 10 (when in its temporary shape10″) and the non-shape memory material 16 together conform to the part12 shape, as will be described in detail below in conjunction with FIGS.2B and 3B. It is to be understood that the examples shown in the FIGS. 2and 3 series are illustrative, and that the shape memory material 10 maybe integrated with the non-shape memory material 16 in any desirablemanner that enables the part 12 to be packaged and de-packaged in adesirable manner. Other such examples are discussed further hereinbelowin reference to the FIGS. 4 and 5 series.

Referring now to the example of the method depicted in the FIG. 2series, the part 12 is placed against one of the portions of thenon-shape memory material 16 (as shown in FIG. 2A). It is to beunderstood that in this example the part 12 is not placed against aportion of the shape memory polymer 10, 10′ so that the part 12 does notrestrict any movement of the shape memory polymer 10, 10′ when itchanges shape. As such, in this example, the shape memory polymer 10acts as a hinge of the packaging material.

As shown in FIG. 2B, the shape memory polymer 10 is deformed from itspermanent shape 10′ into a temporary shape 10″ by heating the shapememory polymer 10, 10′ to a temperature above its switching temperatureand applying a suitable force to the polymer 10, 10′. The heating andthe application of the force may be accomplished according to themethods described hereinabove in conjunction with the FIG. 1 series.When the heat is applied to change the shape memory polymer 10 into itstemporary shape 10″, the non-shape memory material 16 is thermoformed orotherwise deformed such that it generally complies with such movementand conforms to the part shape 12 as a result of traditional plasticdeformation. Examples of such thermoforming/deforming methods includeheating and pressurizing (e.g., via the blister line method describedabove), vacuum forming (as also described above), or other deformingmethods. The temporary shape 10″ of the shape memory polymer 10 and thedeforming and/or thermoforming of the non-shape memory material 16enable the packaging, as a whole, to surround the part 12. For example,as shown in FIG. 2B, a portion of the deformed/thermoformed non-shapememory material 16′ folds over a portion of the part 12, and togetherthe deformed/thermoformed non-shape memory material 16′ and the shapememory polymer 10 in its temporary shape 10″ surround the part 12.

The shape memory polymer 10 is then cooled to a temperature below itsswitching temperature to set the polymer 10 in its temporary shape 10″.It is to be understood that after deforming/thermoforming, the wholematerial is cooled to below the softening/melting temperature of thenon-shape memory polymer 16′, so the switching temperature of the shapememory polymer 10 is set to be lower than that of the deforming orthermoforming operation.

Referring now to FIG. 2C, the part 12 may be de-packaged by heating theshape memory polymer 10 in its temporary shape 10″ to a temperatureabove its switching temperature. When the shape memory polymer 10, 10″is heated to this temperature, the polymer 10, 10″ again reaches its lowmodulus and deformable state and reverts back to its permanent shape10′. The reverting of the shape memory polymer 10, 10′ forces at leastone of the two portions of the previously deformed/thermoformednon-shape memory material 16′ to move away from each other, therebyopening up the packaging and allowing the part 12 to be removedtherefrom. As shown in FIG. 2C, the deformed and/or thermoformednon-shape memory material 16′ may retain the part 12 shape, dependingupon the material used.

Referring now to the example depicted in the FIG. 3 series (where theshape memory polymer 10 in its permanent shape 10′ is located at the end18 of the non-shape memory material 16, as shown in FIG. 3A), the methodincludes deforming/thermoforming the non-shape memory material 16 sothat the deformed and/or thermoformed non-shape memory material 16′substantially surrounds the part 12 (shown in FIG. 3B). Prior to orduring deforming/thermoforming of the non-shape memory material 16, theshape memory polymer 10 is deformed from its permanent shape 10′ intoits temporary shape 10″ (also shown in FIG. 3B). If the shape memorypolymer 10 is deformed prior to deforming/thermoforming, thedeforming/thermoforming temperature is less than the switchingtemperature of the shape memory polymer 10. However, if the shape memorypolymer 10 is deformed during deforming/thermoforming, thedeforming/thermoforming temperature is greater than or equal to orgreater than the switching temperature of the shape memory polymer 10.The switching may be accomplished by heating the shape memory polymer10, 10′ to a temperature above its switching temperature and applying anappropriate force thereto. Then the shape memory polymer 10, 10″ iscooled to a temperature below its switching temperature in order to setthe polymer 10 into its temporary shape 10″. As shown in FIG. 3B, thetemporary shape 10″ of the shape memory polymer 10 in combination withthe non-shape memory material 16 completes the packaging of the part 12.

Referring now to FIG. 3C, the part 12 may be de-packaged by heating theshape memory polymer 10 in its temporary shape 10″ to a temperatureabove its switching temperature. When the shape memory polymer 10, 10″is heated to this temperature, the polymer 10 again reverts back to itspermanent shape 10′. When the polymer 10, 10′ is reverted, the polymer10, 10′ separates from the non-shape memory material 16, opens up thepackaging, and allows the part 12 to be removed therefrom.

As mentioned hereinabove, the FIGS. 4 and 5 series illustrate otherembodiments of using a shape memory polymer 10 with a non-shape memorymaterial 16.

In the FIG. 4 series, the shape memory polymer 10 and the non-shapememory material 16 are two different pieces of the packaging material,as shown in FIG. 4A. The non-shape memory material 16 is thermoformed orotherwise deformed such that it generally conforms to a portion of thepart shape 12 (as shown in FIG. 4B). The shape memory polymer 10 is thendeformed from its permanent shape 10′ into its temporary shape 10″ suchthat it i) conforms to another portion of the part and ii) surrounds theend portions of the thermoformed/deformed non-shape memory material 16′,thereby forming a crimp (also shown in FIG. 4B). The conversion of theshape memory polymer 10 may be accomplished by heating the shape memorypolymer 10, 10′ to a temperature above its switching temperature andapplying an appropriate force thereto. Then the shape memory polymer 10,10″ is cooled to a temperature below its switching temperature in orderto set the polymer 10 into its temporary shape 10″.

The de-packaging of the part 12 is shown in FIG. 4C. To reiterate fromabove, this may be accomplished by heating the shape memory polymer 10in its temporary shape 10″ to a temperature above its switchingtemperature. When the shape memory polymer 10, 10″ is heated to thistemperature, the polymer 10 again reverts back to its permanent shape10′, thereby opening up the crimp and enabling the previouslythermoformed/deformed non-shape memory material 16′ to be separated fromthe part 12.

In the FIG. 5 series, two different pieces are used to form thepackaging material (similar to FIGS. 4A through 4C). However, in thisembodiment, a non-shape memory material 16 is one of the pieces, and theother of the pieces is a composite of the shape memory polymer 10 andanother non-shape memory material 20 (shown in FIG. 5A). In thisembodiment, the shape memory polymer 10 portions of the composite pieceare located at the ends of the non-shape memory material 20.

The non-shape memory materials 16, 20 are thermoformed or otherwisedeformed such that they generally conform to respective opposed portionsof the part shape 12 (as shown in FIG. 4B). The shape memory polymer 10portions are then deformed from their permanent shapes 10′ into theirtemporary shapes 10″ such that each shape memory polymer 10 in itstemporary shape 10″ surrounds one end portion of the thermoformed ordeformed non-shape memory material 16′, thereby forming a crimp (alsoshown in FIG. 4B). The conversion of the shape memory polymers 10 may beaccomplished by heating the shape memory polymer 10, 10′ to atemperature above its switching temperature and applying an appropriateforce thereto. Then the shape memory polymer 10, 10″ is cooled to atemperature below its switching temperature in order to set the polymer10 into its temporary shape 10″.

The de-packaging of the part 12 is shown in FIG. 5C. To reiterate fromabove, this may be accomplished by heating the shape memory polymer 10in its temporary shape 10″ to a temperature above its switchingtemperature. When the shape memory polymer 10, 10″ is heated to thistemperature, the polymer 10 again reverts back to its permanent shape10′, thereby opening up the crimp and enabling both of the previouslydeformed/thermoformed non-shape memory materials 16′, 20′ to be removedfrom the part 12.

It is to be understood that the embodiments depicted in the FIGS. 4 and5 series may further be accomplished by reversing the shape memorypolymer 10 and the non-shape memory material 16 (according to theembodiment depicted in the FIG. 4 series) or by reversing the shapememory polymer 10 composite and the non-shape memory material 16(according to the embodiment depicted in the FIG. 5 series). Forexample, in the embodiment depicted in the FIG. 4 series, the non-shapememory material 16 may be used on the bottom portion of the part 12, andthe shape memory polymer 10 may be used on the top portion of the part12. The respective packaging materials may also be configured tosurround the part 12 from its sides. It is further to be understood thatthe embodiment of the method shown in the FIG. 4 series may also beaccomplished where both pieces are shape memory polymers. Likewise, theembodiment shown in the FIG. 5 series may also be accomplished where onepiece is a shape memory polymer composite and the other piece is a shapememory polymer.

Referring now to FIGS. 6A through 6D, another embodiment of thepackaging and de-packaging methods is shown. In this embodiment, thepermanent shape 10′ of the shape memory polymer 10 corresponds to thedesired part 12 shape (shown in FIG. 6A), and the temporary shape 10″ ofthe shape memory polymer 10 is the more open shape (shown in FIG. 6B).

When setting the permanent shape 10′ of the shape memory polymer 10 asthe part 12 shape, for thermoset materials, the shape in which thepolymer is cured becomes the permanent shape 10′. For thermoplasticmaterials, the material is melted and shaped into the permanent shape10′ using conventional methods such as, e.g., injection molding, blowmolding, and/or the like.

FIG. 6A shows the shape memory polymer 10 already set into the permanentshape 10′. In order to open the polymer 10 into a more open temporaryshape 10″, the shape memory polymer 10 is heated above its switchingtemperature. This heating generally enables the polymer 10 to reach itslow modulus, easily deformable state, and the polymer 10 may then bedeformed by applying some external force (such as those describedhereinabove in reference to the other figures) to conform the polymer 10to the more open temporary shape 10″, as shown in FIG. 6B. The shapememory polymer 10 is then cooled to set the temporary shape 10″ (theshape in which the shape memory polymer 10 is ready for packaging of thepart 12).

FIG. 6B also illustrates the positioning of the part 12 proximate to theshape memory polymer 10 in its temporary shape 10″. It is to beunderstood that the position of the part 12 is selected so that when theshape memory polymer 10 is converted back into its permanent shape 10′,the polymer 10 will conform to the part 12 shape.

Once the part 12 is in a suitable position adjacent to the shape memorypolymer 10, the shape memory polymer 10 is again heated above itsswitching temperature. This heating causes the shape memory polymer 10to spontaneously revert to its permanent shape 10′, thereby surroundingthe part 12, as shown in FIG. 6C. The polymer 10 is then cooled belowthe switching temperature to set the permanent shape 10′ around the part12.

In order to de-package the part 12 in this embodiment, the shape memorypolymer 10, 10′ is again heated above its switching temperature. Uponreaching its low modulus state, the shape memory polymer 10′ may bepulled off of the part 12. The pulling exerted on the shape memorypolymer 10′ may, in an example, be the external force required to deformthe polymer 10 into, e.g., the temporary shape 10″, as shown in FIG. 6D.It is to be understood that the polymer 10 may be deformed into anyother shape (not necessarily the temporary shape 10″ shown in FIG. 6D)that is sufficient for removal of the part 12. Once the temporary shape10″ is achieved, the part 12 may be separated from the polymer 10.

It is to be understood that since heating is and cooling is used toconvert the polymer 10 between its two shapes 10′, 10″ while the part 12is therein, the switching temperature is selected to be i) below alowest melting temperature of the part 12, or ii) below a degradationtemperature of the part 12, or iii) below a melting temperature of acomponent of the part 12 having a lowest melting temperature of allcomponents of the part 12, or iv) below a degradation temperature of acomponent of the part 12 having a lowest degradation temperature of allcomponents of the part 12. It is to be understood that all of thematerials described hereinabove may be suitable for the shape memorypolymer 10 described in FIGS. 6A through 6D.

The embodiment shown in FIGS. 6A through 6D may be particularlydesirable when the packaging material 10 is to be used multiple timesfor the same part 12 shape. Since the permanent shape 10′ of the shapememory polymer 10 is in the part 12 shape, each package may be opened,emptied, and the shape memory polymer 10 sent back to the manufacturerfor reuse with the same type of part 12 with minimal work required topackage the new part 12 using the shape memory polymer 10.

While several embodiments have been described in detail, it will beapparent to those skilled in the art that the disclosed embodiments maybe modified. Therefore, the foregoing description is to be consideredexemplary rather than limiting.

1. A packaging method, comprising: placing a part adjacent to a shapememory polymer in its permanent shape; heating the shape memory polymerin the permanent shape to a temperature above the switching temperatureof the shape memory polymer; applying a force to the heated shape memorypolymer such that it conforms to at least one of i) a shape of the part,or ii) a desired shape for packaging the part, thereby changing theshape memory polymer from the permanent shape into the temporary shape;and cooling the shape memory polymer to a temperature below theswitching temperature to set the shape memory polymer into the temporaryshape.
 2. The method as defined in claim 1, further comprisingde-packaging the part by: heating the shape memory polymer to atemperature above the switching temperature, thereby reverting the shapememory polymer from the temporary shape into a permanent shape, andreleasing the part; and removing the part from the shape memory polymerin the permanent shape.
 3. The method as defined in claim 2 wherein theshape memory polymer is integrated with a non-shape memory material suchthat the shape memory polymer in the temporary shape and the non-shapememory material together conform to the part shape, and wherein thenon-shape memory material is separable from the part when the shapememory polymer is reverted from the temporary shape into the permanentshape.
 4. The method as defined in claim 1 wherein the applying of theforce is accomplished by pressurizing the shape memory polymer, vacuumforming the shape memory polymer around the part, or combinationsthereof.
 5. The method as defined in claim 1 wherein the permanent shapeis more open than the temporary shape.
 6. The method as defined in claim1 wherein the switching temperature ranges from freezing temperature upto about 100° C.
 7. The method as defined in claim 1 wherein theswitching temperature is at least one of: i) below a lowest meltingtemperature of the part, or ii) below a degradation temperature of thepart, or iii) below a melting temperature of a component of the parthaving a lowest melting temperature of all components of the part, oriv) below a degradation temperature of a component of the part having alowest degradation temperature of all components of the part.
 8. Themethod as defined in claim 1, further comprising: thermoforming anon-shape memory material to conform to a first portion of the part; andwherein the applying of the force to the heated shape memory polymer isaccomplished such that the polymer conforms to a second portion of thepart.
 9. The method as defined in claim 1 wherein the shape memorypolymer is integrated with a non-shape memory material such that shapememory polymers are present at each opposed end of the non-shape memorymaterial, and wherein the method further comprises: deforming an otherseparate non-shape memory material to conform to a first portion of thepart; deforming the non-shape memory material that is integrated withthe shape memory polymers such that the non-shape memory materialconforms to a second portion of the part; and wherein the applying ofthe force to the heated shape memory polymers is accomplished such thateach forms a crimp at the opposed end of the other separate non-shapememory material.
 10. A de-packaging method, comprising: providing a partat least partially surrounded by a shape memory polymer in its temporaryshape; heating the shape memory polymer to a temperature above aswitching temperature of the shape memory polymer, thereby reverting theshape memory polymer from the temporary shape into a permanent shape andreleasing the part; and removing the part from the shape memory polymerin the permanent shape.
 11. The method as defined in claim 10 whereinthe shape memory polymer is integrated with a non-shape memory materialsuch that the shape memory polymer in the temporary shape and thenon-shape memory material together conform to the part shape, andwherein the non-shape memory material renders the part separabletherefrom when the shape memory polymer is reverted from the temporaryshape into the permanent shape.
 12. The method as defined in claim 10wherein the reverting of the shape memory polymer from its temporaryshape into its permanent shape opens up the shape memory polymersurrounding the part, thereby enabling the removing of the part.
 13. Themethod as defined in claim 10 wherein the switching temperature rangesfrom freezing temperature up to about 100° C.
 14. The method as definedin claim 10 wherein the switching temperature is at least one of: i)below a lowest melting temperature of the part, or ii) below adegradation temperature of the part, or iii) below a melting temperatureof a component of the part having a lowest melting temperature of allcomponents of the par, or iv) below a degradation temperature of acomponent of the part having a lowest degradation temperature of allcomponents of the part.
 15. A packaging method, comprising: heating ashape memory polymer in its permanent shape above its switchingtemperature, the permanent shape corresponding to a predetermined partshape; applying a force to the heated shape memory polymer such that itchanges from the permanent shape into a temporary shape, the temporaryshape being more open than the permanent shape; cooling the shape memorypolymer in its temporary shape to set the temporary shape; placing apart at a predetermined position adjacent to the shape memory polymer inits temporary shape; heating the shape memory polymer above itsswitching temperature, thereby causing the shape memory polymer tospontaneously revert to its permanent shape and surround the part; andcooling the shape memory polymer to a temperature below the switchingtemperature to set the shape memory polymer into the permanent shape.16. The method as defined in claim 15, further comprising de-packagingthe part by: heating the shape memory polymer to a temperature above theswitching temperature; applying a force to the heated shape memorypolymer such that it changes from the permanent shape into the temporaryshape; and removing the part from the shape memory polymer in thetemporary shape.
 17. The method as defined in claim 15 wherein theswitching temperature is at least one of: i) below a lowest meltingtemperature of the part, or ii) below a degradation temperature of thepart, or iii) below a melting temperature of a component of the parthaving a lowest melting temperature of all components of the part, oriv) below a degradation temperature of a component of the part having alowest degradation temperature of all components of the part.